A flange device for roll-flange a rim of a component includes a flange head, a first flange roller which is mounted by the flange head and can be rolled off on the rim during roll-flange, and a second flange roller which is mounted by the flange head and forms a counter pressure roller for the first flange roller, the flange device including a stable protective structure which is or can be fastened to the component and forms a rolling surface for one of the flange rollers or supports a rolling surface.
A method for roll-flange a component along a flange edge, using a flange device according to claim 1, comprising the steps of: a) positioning the protective structure along the flange edge relative to the component; b) rolling thefirst flange roller off on a rim strip which extends along one side of the flange edge and is to be at least partially beaded around the flange edge; and c) rolling the second flange roller off on an area of the component which extends along theother side of the flange edge, the second flange roller acting as a counter pressure roller for the first flange roller; wherein one of the flange rollers rolls off on a rolling surface formed by the protective structure or on a rolling surfacesupported by the protective structure.
The situation presented, in which an outer part of the body has to be connected to an inner part by hemming, arises for example in the case of wheel arches of vehicle bodies. The outer shell of the body has a circular arced, preferablysemi-circular section, on the rim of which the so-called wheel arch is fastened on the inner side of the body. The problem here is that the outer side of the outer shell should not be deformed or at least deformed as little as possible, i.e. must notfor example receive any dents or scratches, since these would be immediately visible when the outer shell is subsequently painted, and would spoil the aesthetic effect which the vehicle body is intended to impart.
In principle, this therefore prohibits using hemming device comprising pressing and counter pressure rollers, since the counter pressure roller would then run along the outer side of the outer shell and could deform it. The solutions knownhitherto get by using sliders which are moved radially outwards behind the rim of the outer shell, with respect to the wheel section, and thus turn it inwards. Since a counter pressure is omitted here, the quality of the hem is not always satisfactory. Moreover, this is relatively involved equipment which only caters specifically for the body of one type of vehicle in each case, which makes using it in production facilities in which different types of body are built problematic.
The invention relates to a flange device for roll-flange a rim of a component or other work piece along a flange edge, and to a flange method. The flange device preferably forms a hemming device for producing a hem connection. Thecomponent is preferably a body part, as such or already assembled. The invention is then particularly advantageous if the body part forms a viewed area, for example an outer part of the body, in the subsequent finished product, preferably a vehicle.
The invention preferably relates to a device for hemming the rim of a first body part which preferably forms an outer side of a body, wherein the rim of a second body part which for example forms an inner part of the body lies in the hem slot ofthe first body part. The device comprises a flange head with at least one counter pressure roller supported on the outer side of the first body part and preferably at least two pressing rollers which oppose the counter pressure roller or each opposeone counter pressure roller, for successively turning over the rim of the first body part.
It is an object of the invention to turn over the rim of a component, preferably vehicle a body part and in particular an outer metal sheet, using simple means, such that the component is not deformed. The device should also be configured suchthat it can be quickly adapted to different component shapes.
The invention relates to a flange device comprising a flange head, at least one first flange roller and at least one second flange roller which are each pivoted by the flange head. In the case of roll-flange, the first flangeroller forms a pressing roller which rolls off on a rim to be beaded, preferably a narrow rim strip of the component. The second flange roller acts as a counter pressure roller for the first flange roller, i.e. it takes up the force to be applied bythe first flange roller in order to bead the rim strip by for example 30° or 45°. In accordance with their respective function, the first flange roller is referred to below as the pressing roller and the second flange roller isreferred to below as the counter pressure roller. The flange head can in particular be fastened to one end of a robot arm which preferably exhibits all six degrees of freedom of movement, but at least exhibits the degrees of freedom required for theflange process itself.
In accordance with the invention, the flange device further includes a stable protective structure which can be fastened to the component or is fastened during roll-flange. For the counter pressure roller, the protective structure eitherforms a rolling surface itself, on which the counter pressure roller rolls off during roll-flange, or it only forms the rolling surface indirectly, by supporting a rolling surface on which the counter pressure roller directly rolls off. In the firstcase, an inner side of the protective structure abuts the component and is preferably shaped so as to be adapted to its surface. An outer side of the protective structure forms the rolling surface for the counter pressure roller. In the second case,the protective structure is arranged in the inner region of the flange edge to be formed and abuts the inner side of the component, wherein the protective structure is preferably shaped so as to be adapted to the surface of the inner side. Because itis supported on the inner side, the component can itself form the rolling surface for the counter pressure roller in the second case and is nonetheless not deformed by the pressing counter pressure roller, or far less than without the support on theinner side.
If the protective structure forms the rolling surface itself, the counter pressure roller does not roll off directly on the component, but on the protective structure which preferably forms a sort of matrix which is adapted to the inner side ofthe outer contour of the component, such that even the smallest spatial configurations of the component can be exactly copied and deformations need not be feared. The flange head itself can be a standard type which can also be used for other flangeprocesses. Above all, this has the advantage that a number of different bodies can be processed for example on a production line for vehicle bodies, preferably automobile bodies. It is merely necessary to retain respectively adapted protectivestructures which can be initially placed onto the body or inserted in the inner region of the flange edge, before the flange process is started.
In preferred embodiments, the area of the protective structure with which the protective structure abuts the area to be protected is shaped so as to conform to said abutting area of the component, such that the protective structure and thecomponent abut full-face.
The bodies and the protective structure preferably each have at least one marker which allows the protective strip to be placed in an exact fit on the rim to be flanged over. The at least one marker on the body can be a contour or edge which isinherently predefined, such as sections for doors, beams or the like. At least one hole can also be specifically introduced. In preferred embodiments, the protective structure possesses a centring element, preferably a positioning pin, and at least onestopper element which is used as a contour abutment. Alternatively, the protective structure can also be provided with just two centring elements, preferably positioning pins, or with just two stopper elements. Using such pairs of positioning meanswhich co-operate with corresponding positioning means of the component or--in the assumed example--with the body, the protective structure is exactly positioned relative to the flange edge when it abuts the abutting area of the component. In thealternative embodiment, in which the protective structure is arranged in the inner region of the flange edge, a single positioning element--preferably a stopper element--can be sufficient for positioning.
In one development, the flange head mounts a third flange roller which forms another counter pressure roller for at least one of the first flange roller and the second flange roller in a flange process. A closed flow of force may beobtained by means of such a third flange roller. Such an embodiment is particularly advantageous for a protective structure arranged in the inner region of the flange edge. The third flange roller, acting as a suppressor, can also serve to fastenthe protective structure. Thus, in particular in a protective structure arranged in the inner region of the flange edge, an additional fastening can even be completely omitted. In principle, this also applies to a protective structure abutting on theoutside.
In another development, a sensing element is fastened to or formed on the flange head, preferably pivoted as a sensing roller, in addition to the at least two flange rollers, and the protective structure forms a guiding path for the sensingelement, preferably another rolling surface, which follows the course of the flange edge. The sensing element, which is guided on the guiding path along the flange edge in a flange process, in turn guides the flange head, enabling theexpenditure which has to be made for controlling the movements of the flange head, in particular the measuring expenditure, to be reduced. For roll-flange along the flange edge, it is in principle even possible to completely omit controlling orregulating on the basis of positional signals obtained by measurement. If the flange head is guided along the flange edge by means of a sensing element, by guiding the guiding element on a guiding cam which is preferably formed by the protectivestrip but could in principle for example also be formed by the flange edge itself, the flange head is preferably mounted such that it can move back and forth in a direction pointing at least substantially normally with respect to the guiding path,preferably against an elastic restoring force. The elastic restoring force can expediently be a pneumatic force.
Advantageously, a sensor, preferably a distance sensor, is provided. The sensor is preferably mounted on the flange head or a platform to which the flange head is fastened. By means of the sensor the distance between the flange head andthe component or the protective structure can be ascertained. The sensing element can be replaced by a distance sensor which operates without contact, by moving the distance sensor along the guiding path described with respect to the sensing elementduring roll-flange, constantly measuring the distance without contact, and using the readings to regulate the movement of the flange head. A 1D sensor is sufficient as the distance sensor.
In developments, a two-dimensional sensor is provided which operates without contact, i.e. a 2D sensor using which the position of the flange head relative to the component, in particular its flange edge, can be ascertained in a plane of viewonto the component. The 2D sensor is preferably mounted on the flange head or a platform to which the flange head is fastened. In the preferred application--roll-flange on a body part--the plane of view extends in the XZ plane of the usualco-ordinate system of vehicle bodies. This sensor system is only required, and in advantageous method embodiments also only used, to place the flange head for roll-flange on the flange edge. If a mechanical sensing element or the distance sensorcited is not provided, the 2D sensor or another substitute sensor system, for example two 1D sensors, can also be used to regulate the movements of the flange head during roll-flange. Preferably, however, the 2D sensor system is provided in additionto the sensing element or distance sensor cited. Sensing and regulating in the XZ plane is particularly advantageous for hemming a so-called drop flange.
If, however, it may be assumed that the components to be flange always assume the positionprovided for roll-flange with sufficient accuracy, and are themselves always shaped with sufficient accuracy, then a 2D sensor system can be omitted, since in this case, it is possible to rely on the fact that it is sufficient if the flange headmoves to a predefined position, for example a pre-programmed position. In the circumstances cited, the sensing element and the distance sensor can also be omitted.
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